Lenticular label manufacture

ABSTRACT

A process for forming lenticular labels on a continuous web so that the lenticules are perpendicular to the longitudinal axis of the web. The process includes the steps of: advancing a continuous web of label stock including an adhesive on both sides; providing multiple sheets of lenticular assemblies; and securing the sheets of lenticular assemblies to one side of the continuous web with that lenticules of the lenticular assemblies oriented perpendicularly to the length of the continuous web.

This is a division of application Ser. No. 09/800,868, filed Mar. 7, 2001, now U.S. Pat. No. 6,596,361 B2.

BACKGROUND

The present invention relates to labels and more particularly to the manufacture of labels including lenticular lenses.

Lenticular lenses are known and used in the printing of advertising and promotional materials, packaging labels, hang tags for merchandise, product tags, and security labels. Lenticular lenses are thin, transparent lenses that are flat on one side and include a plurality of parallel, linear, side-by-side lenticules—elongate, convex lenses—on a second side. Typically, an image is printed on the flat side to create a visual effect of zoom-in, zoom-out, steroscoping, three-dimensional sequencing, or movement of the image when viewed through the lenticules. The combination of a lens and an image is referred to as a lenticular assembly.

Lenticular assemblies are manufactured in a continuous web with the lenticules being parallel to the longitudinal axis of the continuous web. In one manufacturing process, concave machine guides fit over the convex lenticules as the web advances to ensure exact registration between images printed on the flat side and the lenticules.

In a popular application, the web of lenticular assemblies is applied to a web of transfer tape on a release liner or carrier web. The adhered lenticular assemblies and tape are die cut to create a continuous web of pressure sensitive lenticular labels. The resultant product is a continuous web of lenticular labels having the lenticules oriented parallel to one another and the length or the longitudinal axis of the web.

The resulting web of lenticular labels suffers a number of shortcomings. Most significantly, the orientation of the lenticules extending the length of the label web governs the orientation of the desired visual effect. Specifically, as a result of the lenticules' orientation, the intended visual effect on the continuous label web may be viewed in only two ways; (1) by rotating the continuous web along an axis parallel to the length of the web, and (2) by moving the web so that a viewer's sight line moves across the width of the web, that is, perpendicular to the length of the web.

When labels are applied from the resulting web to objects, such as bottles, using conventional labeling equipment, the lenticules are oriented circumferentially on the object (i.e. perpendicular to the height of the object). Consequently, the visual effect occurs only when the viewer and the labeled object move vertically relative to one another. Because continuous lenticular assemblies are available only with lenticules parallel to the direction of travel, the conditions under which the visual effects occur have been limited.

SUMMARY OF THE INVENTION

The aforementioned problems are overcome in the present invention wherein the lenticules of lenticular labels on a continuous web are oriented transversely to the longitudinal axis of the web.

The process of manufacturing the web includes the steps of: providing a continuous web of label stock with adhesive on both sides, placing sheets of lenticular assemblies on one side of the continuous web with the lenticules of the lenticular assemblies transverse to the length of the continuous web; and optionally die-cutting the lenticular assembly/label stock to form individual labels.

When the lenticular labels are applied with conventional continuous labeling equipment to a vertically standing article, for example, a bottle, the desired visual effect is perceived by a viewer either (1) as the article is rotated about its longitudinal axis or (2) as the viewer walks past the vertically standing article.

These and other objects, advantages and features of the invention will be more readily understood and appreciated by reference to the detailed description of the preferred embodiments and the drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of the continuous lenticular label web manufacturing process of the present invention;

FIG. 2 is a perspective view of the continuous lenticular label web manufacturing process with individual lenticular labels being formed;

FIG. 3 is a perspective view of individual lenticular labels being applied from a web onto articles using conventional equipment;

FIG. 4 is a top plan view of individual lenticular labels being applied from a web onto articles using conventional equipment;

FIG. 5 is perspective view of a viewer perceiving a lenticular label manufactured according to the process of the present invention and applied using conventional equipment;

FIG. 6 is a perspective view of an alternative construction of a lenticular assembly of the continuous lenticular label web.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

In the preferred embodiment, the present invention is described in connection with the manufacture of a continuous lenticular label web and the application of individual labels to articles. With reference to FIGS. 1 and 2, the lenticular label web 10 of the preferred embodiment is constructed from sheets of lenticular assemblies 20 secured to a label assembly 50, which is in the form of a continuous web.

The lenticular assembly 20 includes a lenticular lens 24 associated with a visual effect image 22 to provide an illusion. As desired, a plurality of images 22 may be associated in any configuration on the lenticular assembly 20. The visual effect image 22 may include any combination of graphics, text, or other visual information. As used herein, “visual effect image” means an image that creates illusions such as “flips”, “3-D” or stereographic, full motion video, “morphing”, and zooming. A “flip” represents an abrupt change from one viewed image to another, different image “3-D” effects produce an illusion of depth for an object being viewed. Full motion video produces a sense of movement of an object being viewed as the viewing angle changes. “Morphing” produces an illusion of a metamorphosis (transition) from one image to another as the viewing angle changes. Zooming presents a size change in an object being viewed, the object appearing to move either closer to, or away from, the viewer.

The lenticular assembly 20 may be of various constructions, including the preferred construction depicted in FIG. 1, where lenticular lens 24 has an image printed on the flat side 26, opposite the lenticules 28. The image may be printed on the flat side 26 using conventional lenticular lens printing methods, which, as will be appreciated, require precise registration of the images 22 with respect to the lenticules 28 to ensure the image is viewed through the lenticular lens with the intended visual effect.

In an alternative construction, depicted in FIG. 6, the lenticular assembly 120 includes a lenticular lens 124 secured with a conventional, permanent adhesive 129 to lenticular stock 130 on the flat side 126 of the lenticular lens 124, opposite the lenticules. The lenticular stock 130 has an image 122 printed thereon that is precisely aligned with the lenticules 128 in a conventional manner to provide the intended viewing effect. The lenticular stock 130 may be of any material or combination of materials including, but not limited to paper, plastic, or metal foil.

In the preferred embodiment, depicted in FIGS. 1 and 2, the lenticular assemblies 20 are provided in sheet form. The lenticular assemblies 20 are secured to the continuous web of label assemblies 50 so that the direction L in which the lenticules extend in parallel is offset some angle A from the direction W coincident with the length of the continuous web, also known as the direction/line of advancement, or the direction/line of travel of the web. The lenticular assemblies 20 may be secured to the continuous web of label assemblies 50 with any suitable adhesive, but preferably with permanent adhesive 52.

The label assembly 50 is preferably in continuous web form, as depicted in FIGS. 1-6. Label assembly 50 includes label stock web 56, which may be constructed of any suitable material or combination of materials including, but not limited to paper, plastic, or metal foil. On a first side of the stock 56, an adhesive 52 is disposed to secure sheets of lenticular assemblies 20 to the label assembly 50. Preferably the adhesive is a conventional permanent adhesive, but other adhesives may be used as the application requires. On the opposite side of the stock 56, a second adhesive 58 is disposed. Adhesive 58 is preferably a pressure sensitive adhesive, but also may be any conventional adhesive as the application requires.

Adhesive 58 secures sock 56, and ultimately the web of label assembly material 50 to liner 60, which is preferably a silicone coated release liner, but may be any suitable carrier liner.

Method of Manufacture

With reference to FIGS. 1-4, there will now be described the preferred process of the present invention of manufacturing a continuous lenticular label web. Individual labels from the continuous web manufactured by the preferred process are preferably applied using conventional labeling equipment to vertically standing articles.

The preferred process generally includes the steps: providing multiple sheets of lenticular assemblies; providing a continuous web of label stock including a first side with a pressure sensitive adhesive disposed thereon and a second side with a permanent adhesive disposed thereon; and securing the sheets of lenticular assemblies to the continuous web with the permanent adhesive so that lenticules of the lenticular assemblies extend in a direction that is offset a pre-selected angle from a direction coincident with the length of the continuous web.

As depicted in FIGS. 1 and 2, the lenticular assemblies 20 are provided in sheet form. With conventional equipment, the sheets are positioned on the permanent adhesive 52 to secure the sheets of the lenticular assemblies 20 to the label assembly web 50. When the sheets are adhered to the web 50, the lenticules 28 of the sheets of lenticular assemblies 20 extend in direction L which is non-coincident with and at some angle A from direction W. Angle A is between about 0 and 180 degrees, preferably, between about 45 and 135 degrees, more preferably, about 80 to about 110 degrees, and most preferably, about 90 degrees. At about 90 degrees (depicted in FIGS. 1 and 2), the direction in which the lenticules extend L is substantially perpendicular to direction W. The sheets of the lenticular assemblies 20, depicted in the figures as rectangular, may be of any shape or size and may include any number of visual effect images to form individual lenticular labels.

When the sheets of lenticular assemblies 20 are successfully adhered to the label assembly web 50, the resultant combination is a lenticular label assembly web 70. The web 70 is advanced to a conventional cutting station 75 where individual lenticular labels 80 are cut. The cutting station may implement any conventional cutting method to cut the web, such as roller die-cut (as depicted) or laser cut methods. The web may also be cut into labels in any conventional manner, for example by butt-cutting the labels, where no skeleton waste from excess material is created, or by skeleton cutting the labels, where such waste is created. If skeleton cutting methods are used, the waste matrix 84 generated may be removed from the web 70 and rolled on collector 92 (FIG. 2).

Notably, the individual lenticular labels 80 created remain on the release liner 60. The lenticules 28 of the individual labels 80 remain oriented and extending in the same direction L as when the lenticular assemblies were first positioned on the label assembly web. Accordingly, in the preferred process, all the labels 80 on the web have lenticules extending in direction L, which is about perpendicular to direction W.

Additionally, it is preferred to cut the lenticular label web into sub-webs 72 that include single rows of lenticular labels 80 on the release liner 60. This is so the labels from the sub-webs 72 can easily be applied on individual articles one at a time. The sub-web cutting may be performed in any conventional manner. As depicted in FIG. 2, roller die-cutter 98 cuts the sub-webs 72.

In another step, the individual labels 80 are applied to articles 100 using the conventional continuous labeling equipment as depicted in FIGS. 3 and 4. As depicted, the lenticular label sub-web 72 includes only one row of labels 80. The labels 80 are positioned at application station 94 immediately adjacent the article, here depicted as a cylindrical container 100. Without rotating the label 80 to change the lenticule orientation L, the article 100 is rotated adjacent the label 80 with belts 95 and 97 and plate 93 as depicted. The label 80, is peeled off the sub-web 72 with peel knife 91. By way of the pressure sensitive adhesive thereon, the label 80 catches and adheres onto and around the article 100. As the article rotates, the label 80 is peeled off liner 60 and wraps onto the article 100. The liner 60 is guided away from the application station 94 and collected by liner guide 96. The labeled article 101 is conveyed away from the application station 94 by conveyor 97 and another article is labeled.

With reference to FIGS. 3 and 5, the label 80 applied to the article 100 according to the preferred process is consequently oriented so the lenticules extend in parallel in direction L, which is substantially parallel with the longitudinal axis C of the cylindrical article 101. As depicted in FIG. 5, with the orientation of the lenticules L parallel with the longitudinal axis C, the intended visual effect image is viewable by a viewer V when the article 101 is rotationally translated or horizontally translated. Rotationally translated means rotated about the longitudinal axis C of the article 101 in direction R as depicted in FIG. 5. Translated horizontally means moved across the viewer's line of sight S in direction H as depicted in FIG. 5. Of course, horizontal translation may occur when the article 101 itself is moved by a viewer, or when a viewer walks past an article, for example, when a viewer walks past an article displayed on a shelf.

The above descriptions are those of the preferred embodiments of the invention. Various alterations and changes can be made without departing from the spirit and broader aspects of the invention as defined in the appended claims, which are to be interpreted in accordance with the principles of patent law including the doctrine of equivalents. Any references to claim elements in the singular, for example, using the articles “a,” “an,” “the,” or “said,” is not to be construed as limiting the element to the singular. 

1. A method of manufacturing a lenticular label construction comprising the steps of: advancing a continuous carrier web in a first direction; providing sheets of lenticular assemblies including lenticules oriented in a second direction; and serially securing the sheets of lenticular assemblies to the continuous carrier web to form a lenticular label construction wherein the second direction of lenticule orientation of the sheets of lenticular assemblies is substantially perpendicular to the first direction of advancement of the continuous carrier web, wherein the lenticules of adjacent sheets of lenticular assemblies are aligned in parallel on the continuous carrier web.
 2. The method of claim 1 wherein the continuous carrier web includes a stock layer having first and second sides, a release liner secured to the stock layer with a pressure sensitive adhesive on the first side, and a permanent adhesive disposed on the second side of the stock to secure the sheets to the continuous carrier web.
 3. The method of claim 2 comprising the step of cutting individual labels from the lenticular label construction.
 4. The method of claim 3 wherein said cutting step comprises one chosen from butt-cutting and skeleton cutting.
 5. The method of claim 4 comprising rolling the continuous carrier web onto a spool.
 6. The method of claim 5 wherein said cutting step produces a plurality of sub webs of lenticular labels, wherein the lenticules of first individual labels of a first sub web are oriented parallel to the lenticules of second individual labels of a second sub web adjacent the first sub web.
 7. A method for constructing lenticular labels comprising the steps of: providing a label assembly carrier web secured to a release liner web with a pressure sensitive adhesive; advancing the label assembly carrier web secured to a release liner web with a pressure sensitive adhesive along a line of travel; providing a plurality of lenticular assemblies, each lenticular assembly including a plurality of lenticules, said lenticules parallel to a line of orientation; securing the plurality of lenticular assemblies to the label assembly carrier web with an adhesive to create a lenticular label web, including a plurality of lenticular labels wherein the line of orientation of the lenticules is offset a preselected angle from a direction coincident with the line of travel of the carrier web; and forming a plurality of lenticular labels on the lenticular label web.
 8. The method of claim 7 wherein said forming step includes cutting through the lenticular assembly and label assembly carrier web so that the lenticular labels are formed on the release liner.
 9. The method of claim 7 comprising rolling the continuous carrier web onto a spool.
 10. The method of claim 7 wherein said forming step produces a plurality of sub webs of lenticular labels, wherein the lenticules of first individual labels of a first sub web are oriented parallel to the lenticules of the second individual labels of a second sub web adjacent the first sub web.
 11. The method of claim 7 comprising dividing the lenticular label web into a plurality of adjacent, parallel sub webs.
 12. A process for continuously manufacturing lenticular labels, comprising the steps of: securing a plurality of separate lenticular label assemblies to a carrier web having a line of travel to form a continuous lenticular label web, the lenticular label assemblies including a plurality of lenticules oriented parallel to a line of orientation that is substantially perpendicular to the line of travel; and cutting the continuous label web and the label assemblies to form individual lenticular labels.
 13. The process of claim 12 wherein the lenticular labels include visual effect images.
 14. The process of claim 12 wherein the lenticular labels include a label stock and an ink layer, the ink layer cooperating with the lenticules to create a visual effect image.
 15. The process of claim 12 comprising dividing the continuous label web into a plurality of adjacent, parallel sub webs.
 16. The process of claim 12 comprising the step of spooling the continuous label web to ready the web for transferring the lenticular labels to a plurality of cylindrical articles having a longitudinal axis so that the lenticular labels display a desired illusion when the articles are rotated about the longitudinal axis.
 17. The process of claim 15 comprising the step of separating the plurality of sub webs from one another. 